Knock-down pallet carton



March 20, 1962 c. F. SEVERN KNOCK-DOWN PALLET CARTON 2 Sheets-Sheet 1 Filed Aug. 29, 1960 JNVENTOR. Clare F. Severn ATTORNEY March 20, 1962 c, SEVERN KNOCKDOWN PALLET CARTON Filed Aug. 29, 1960 2 Sheets- Sheet 2 INVENTOR. Clare E Severn/ g a/W ATTORNEY 3,026,015 KNOCK-DOWN PALLET CARTON Clare F. Severn, 11400 Liberty St., Clio, Mich. Filed Aug. 29, 1960, Ser. No. 52,435 Claims. (Cl. 229-41) This invention relates to a combination pallet and carton and more particularly to a reusable pallet carton which can be knocked down after use for convenient shipment and storage until reused.

enerally, the present invention consists of a four-sided carton composed of cardboard, paper, or other suitable material, including two pair of opposing top flaps, two pair of opposing bottom flaps, a plurality of pairs of elongated, flanged, cardboard channel members, rectangular in cross section, in spaced parallel relationship, each pair attached, respectively, to a pair of opposing bottom flaps of said carton, or to reinforcing panels in turn attached to said opposing bottom flaps, to form a plurality of pairs of tubes in spaced, parallel arrangement, each pair having their longitudinal axes in mutual axial alignment when said bottom flaps are closed to form a plane bottom for said carton, and an equal number of elongated pallet inserts, each having a rectangular cross section sufficient to slideably and snugly fit within an axially aligned pair of tubes and of length sufficient to approximately fill said pair of tubes, for insertion therein when the tubes are in axial alignment, to close the bottom of said carton and to support the contents thereof, when it is desired to use said carton for container purposes, and to be removable therefrom so as to permit said carton to be folded substantially flat for convenient shipment and storage until reused.

it is accordingly an object of this invention to provide a foldable cardboard carton with attached, foldable pallet means cooperating therewith. Another object of this in vention is to provide a cardboard carton with attached pallet means wherein said pallet means retains bottom flaps of said carton in closed position for use but permits said carton to be folded compactly when not in use. A further object of the invention is to provide a cardboard carton having attached pallet means wherein elongated pallet inserts provide continuous bottom support for the carton, said support extending substantially between two opposing sides of said carton. A further object of this invention is to provide pallet means including elongated, cardboard channels each of the pallet inserts for which may be conveniently replaced by a piece of lumber of the standard dimensions of that conventionally known as a dressed 2 x 4 board, to-wit: approximately 1% inches by 3% inches. Other objects and advantages of the invention'will be apparent during the course of the following description.

In the accompanying drawings, forming a part of this specification, and in which like characters are employed to designate like parts throughout the same,

FIGURE 1 is a perspective view of a knock-down pallet carton disposed for use.

FIGURE 2 is a perspective view of a knock-down pallet carton in folded disposition.

FIGURE 3 is a perspective view of a pallet insert for a knock-down pallet carton.

FIGURE 4 is a bottom view of a knock-down pallet carton disposed for use.

FIGURE 5 is a sectional view in elevation taken on line 5-5 of FIGURE 4.

FIGURE 6 is a sectional view in elevation taken on line 6-6 of FIGURE 5,.

Referring now more particularly to. the drawings, 11 indicates a conventional four-sided carton composed of cardboard, paper, or other suitable material consisting of sides 12, 13., 14, and 15, a pair of top end flaps 16 and 2 17, a pair of top side flaps 18 and 19, a pair of bottom end flaps 2t? and 21, and a pair of bottom side flaps 22 and 23. Conventionally, such cartons are cut from a single piece of cardboard and fastened by glue, tape, or staples 24, to form a tube having a plurality of flat sides, usually four in number which, in combination with the bottom flaps, may be disposed to form a box closable at the top or, in the alternative, folded flat for shipment and storage. While I have shown for purposes of illustration a carton rectangular in horizontal cross section, it is to be understood that my invention is not limited to rectangular cartons but may be utilized with cartons of any cross section including cartons having a square cross section.

A pair of reinforcing panels 25 and 26 are attached by glue, staples, or other suitable means, respectively, to bottom side flaps 22 and 23, respectively, of carton 11. The use of reinforcing panels is not necessary but, in practice, has been found desirable for the purpose of distributing the load of the cargo within the carton more uniformly to the channel members and inserts hereinafter described.

A pair of rectangular strips of cardboard 27 and 27' each of width equal to or slightly less than the width of a bottom side flap are each folded along four spaced parallel lines perpendicular to the longitudinal axis of each of said strips to form a pair of elongated, flanged channel members having rectangular channel cross sections and a pair of outer flanges. The flanges of each channel member are then fastened by glue or other suitable means, as staples 28, to the outerside of reinforcing panels 25 and 26, respectively, to form, in combination with said rein-forcing panels, a pair of collapsible tubes generally indicated by the numerals 29 and 29 each of which can be disposed in rectangular cross section as best illustrated in FIGURE 5 and, when desired, folded substantially flat as best illustrated in FIGURE 2. I have found it desirable to fold cardboard strips 27 and 27 along parallel ines so spaced as to form, in combination with the reinforcing panels, or with the bottom side flaps if no reinforcing panels are provided, collapsible tubes which, when disposed in hollow, rectangular cross section have internal dimensions equal to or slightly greater than the standard external dimensions of the board conventionally known as a dressed 2 x 4, to-wit: 1% inches by 3% inches. The flanges formed from the outer portions of strips 27 and 27' may be of any convenient width. While I have shown and described staples 28 as being used in single and double rows to fasten the flanges of strips 2'7 and 27' to the reinforcing panels or, in their absence, to the bottom side flaps, it is to be understood that any convenient means, as for example glue, may be used for this purpose. Tubes 29 and 29 are so disposed that when bottom side flaps 22 and 23 are folded inward to form, a plane bottom for carton Ill, the longitudinal axes of tubes 2-9 and 29' will be in alignment.

Additional pairs of cardboard strips 30 and 3t), and 31 and 31, are similarly folded and attached to reinforcing panels 25 and 26 or, in their absence, bottom side flaps 22 and 23, to form two additional pairs of collapsible tubes, 32 and 32', and 33 and 33', each being disposable in rectangular cross section or, if desired, folded substantially flat, and each respective pair being mutually in longitudinally axial alignment when bottom side flaps 22 and 23 are folded inward to form a plane bottom for carton it.

A space or gap may be left between the respective inner ends of each mutually alignable pair of tubes, if desired, as space 34 shown between tubes 29 and 2 9, but this is not necessary nor an esesntial feature of my invention.

While I have shown my invention as having three pairs of tubes attached to the reinforcing panels, or, in their absence, to the bottom side flaps, it is to be understood that my invention is not restricted to the use of three tubes but that only two tubes, or any number greater than two, may be used if desired. in the embodiment shown in the drawings, I have illustrated the two outside pairs of tubes as being located closer to the outer ends of carton 11 than to center tubes 32 and 32, to provide stability for the pallet carton when erected. The space between each parallel pair of tubes is such as to distribute to the tubes as evenly as possible the load of the cargo contained within carton 11 and to permit the fork of a conventional fork lift or truck having mechanical fork-type lift means to be inserted beneath the carton and between the said tubes to engage and lift the pallet carton for convenient moving and storage of the pallet carton and cargo therein. I have found it desirable to form the flanges of each axially alignable pair of tubes of such width as to space said tubes from the pair or pairs of tubes attached parallel to them in the array and to provide additional support for the bottom flaps of carton 11.

A pallet insert 35 composed of laminated corrugated cardboard is provided for each aligned pair of tubes. Pallet insert 35 has a rectangular cross section of dimensions such as to slideably and snugly fit within an axially aligned pair of tubes and of a length approximately equal to the distance between the outer ends of each pair of tubes when aligned, so as to approximately fill said tubes when inserted within them. i

While laminated corrugated cardboard" inserts have been found most desirable for this purpose, it is not to be understood that my invention is limited to the use of such material. Where a replacement for a cardboard insert must be found quickly, or where extremely heavy cargos are to be supported, or where the pallet carton must stand in moisture, I have found it desirable to utilize inserts constructed of wood. For this purpose, I have found it most convenient to construct the cardboard tubes with cross sections such as to slideably and snugly embrace a standard, dressed 2 x 4 board having as its dimensions a thickness of approximately 1% vinches and a width of approximately 3 /8 inches. Where extreme cargo loads are involved, the number of support tubes may be increased or one or more support tubes may be increased in width to accept a wider insert. For this purpose a tube having an internal height of 3% inches and a width of 3 inches may be utilized so as to accommodate as an insert a pair of 2 x 4 boards side-by-side. For normal loads, however, inserts made of laminated strips of corrugated cardboard have been found quite satisfactory and very inexpensive, being able to be manufactured from waste material and salvage from damaged cardboard cartons as well as from new material. There is also less invitation to pilferage of laminated corrugated cardboard inserts than of wooden inserts. The inserts, whether of cardboard or wood construction, snugly fit and are frictionally held within the tubes and thereby prevented from shifting longitudinally.

It is important to note that the inserts, when inserted within a pair of aligned tubes, retain said tubes rigidly in mutually aligned relationship and retain bottom side fiaps 22 and 23 of carton 11 in closed position. Removal of the inserts permits bottom side flaps 22 and 23 to swing open and the pallet carton to be folded flat and for convenience in transport and storage until desired to be reused. With the inserts removed, the tubes may be folded into an approximately fiat disposition upon their respective bottom side flaps or reinforcing panels. A pair of collapsed cartons will tend to nest when stacked, and, by alternating pairs of stacked cartons with respect to the tops and bottoms of each such pair, a substantially stable stack of considerable height may be obtained for convenience in shipping and storage. The inserts, being rectangular in cross section, also stack conveniently for the same purpose.

tit

' slippage of the bands.

When a collapsed pallet carton has been returned or stored and it is desired to utilize it as a container, the carton may be opened, the bottom end flaps folded inward and the bottom side flaps with attached tubes thereafter also folded inward to form a bottom, all in the conventional manner. No glue, staples, or other means are required, however, to retain the bottom flaps in closed position, this function being performed by the tube inserts. A tube insert is then inserted through each mutually aligned pair of pallet tubes where it is frictio-nally retained. The pallet carton is now ready to receive cargo. Upon being filled, the carton top may be closed and sealed in any convenient manner. The pallet carton may be conveniently moved by use of a fork lift or other apparatus which provides forks which can enter under the carton and between the pallet tubes to lift the pallet carton and cargo contained therein for stacking in tiers and loading aboard transport vehicles. If desired, metal bands may be secured about the carton to bind same. It may be noted that the bands may be inserted through the pallet tubes prior to the insertion of the pallet inserts so as to be retained against the tops of the pallet tubes by the tops of their respective inserts when the same have been inserted, the tubes thus serving to prevent lateral However, substantially the same result may be obtained after the pallet inserts have been inserted into the pallet tubes, by merely securing the bands around the carton between parallel pairs of aligned pallet tubes, the pallet tubes and inserts providing space beneath the carton so that bands may be easily secured even though the carton has been previously loaded with cargo, it thus not being necessary to lift the carton in order to thread the bands beneath same for this purpose.

Following use, the pallet carton need not be destroyed but may be easily collapsed and shipped or stored, or both, for reuse. To accomplish this, the pallet inserts are removed, the bottom side flaps and bottom end flaps of the pallet carton opened, and the pallet carton folded flat. The pallet cartons may be stacked in nesting pairs, each pair alternately arranged, as hereinabove described, to form substantially stable stacks of considerable height, and the pallet inserts also stacked, for convenient storage or shipment or both.

It is to be understood that the form of my invention herewith shown and described is to be taken as a preferred example of the same and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of my invention or the scope of the subjoined claims.

Having thus described my invention, I claim:

1. A collapsible and reusable pallet carton comprising, a cardboard carton including a pair of foldable 0pposing bottom flaps, a plurality of pairs of elongated, flanged cardboard channel members in spaced, parallel relationship, each pair attached to a pair of opposing bottom flaps of said carton to form a pair of tubes having their longitudinal axes in mutual axial alignment and transverse to the folds of said bottom flaps when said bottom flaps are closed; and a plurality of elongated pallet inserts each cooperating with a pair of tubes, respectively, and being of cross section sufiicient to slideably and snugly fit within said tubes and of length sulficient to approximately fill said tubes when said tubes are in alignment to releasably retain said bottom flaps in closed position when inserted within a pair of tubes and to permit said bottom flaps to be unclosed and said carton to be collapsed when said inserts are withdrawn from said tubes.

2. A collapsible and reusable pallet carton comprising, a cardboard carton including a pair of foldable opposing bottom flaps; a pair of reinforcing panels attached, respectively, to said pair of bottom flaps; a plurality of pairs of elongated, flanged cardboard channel members, rectangular in cross section, in spaced parallel relationship, each pair attached, respectively, to said pair of re inforcing panels to form a pair of tubes having their longitudinal axes in mutual alignment transverse to the folds of said bottom flaps when said bottom flaps are closed; and an elongated pallet insert for each pair of tubes, said insert having a rectangular cross section sufiicient to slidably and snugly fit within such pair of tubes and of length sufficient to approximately fill such pair of tubes when said bottom flaps are closed to retain said bottom flaps in closed relationship, and to permit said bottom flaps to be unclosed and said carton to be collapsed when said inserts are withdrawn from said tubes.

3. In a cardboard carton having a pair of mutually opposing folded bottom flaps, the improvement comprising, a plurality of pairs of elongated, flanged, cardboard channel members, each pair attached, respectively, to said opposing bottom flaps to form pairs of opposing tubes having rectangular cross sections with their longitudinal axes in mutual alignment and transverse to the folds of said bottom flaps when said bottom flaps are closed, said bottom flaps being unfoldable to dispose said carton in a substantially fiat configuration when said pairs of tubes are not internally supported and retained in alignment by a pallet insert, and a plurality of pallet inserts removably embraced within each said pair of tubes when aligned, each insert being of a lentgh sufiicient to extend approximately between the outer ends of said aligned tubes, to internally support and releasably retain said aligned tubes in rectangular cross section and in mutual, coaxial alignment and said bottom flaps in plane relationship.

4. In a cardboard carton having a pair of folded opposing bottom flaps, a bottom retaining and pallet means comprising, a plurality of cardboard strips each folded and attached to said bottom flaps so as to form, in combination therewith, alignable pairs of elongated hollow cardboard tubes, rectangular in cross section, in spaced, parallel relationship, each alignable pair of tubes having their longitudinal axes in mutual alignment and transverse to the folds of said bottom flaps when said bottom flaps are closed; and an equal number of elongated laminated corrugated cardboard inserts of rectangular cross section sufiicient to be removably embraced within each aligned pair of tubes and of length sufficient to extend approximately between the outer ends of said aligned tubes to releasably retain said bottom flaps in closed position when inserted within a pair of tubes and to permit said bottom flaps to be unclosed and said carton to be collapsed when said inserts are withdrawn from said tubes.

5. A knock-down pallet carton adapted for repeated erection and collapse comprising, a four-sided cardboard box having a pair of opposing top end flaps, a pair of opposing top side flaps, a pair of opposing bottom end flaps, and a pair of opposing folded bottom side flaps; a reinforcing panel attached to each of said bottom side flaps; a plurality of cardboard strips each folded along spaced, parallel lines to form a channel having a rectangular cross section and a pair of flanges flanking said channel, each channel attached by its flanges to one of said reinforcing panels to form a plurality of pairs of tubes in spaced, parallel relationship, each pair arranged in mutual, longitudinal axial alignment transverse to the folds of said bottom flaps when said bottom flaps are folded to form a plane bottom for said carton, each tube being extendable into a rectangular internal cross section approximately 1% inches in width and 3 /8 inches in height; and an elongated, laminated, corrugated cardboard insert for each mutually alignable pair of tubes, each insert being of rectangular cross section approximately 1% inches in width and 3% inches in height and of length approximately equal to the distance between the outer ends of each of said mutually alignable pairs of tubes when the same are in aligned position, to be removably, and coaxially embraced within said pair of tubes when said tubes are aligned to releasably retain said bottom flaps in folded position to form a carton, and disposed to be withdrawn from said tubes to permit said bottom flaps to be unfolded and said carton to be collapsed.

References Cited in the file of this patent UNITED STATES PATENTS 2,142,142 Newsom Jan. 3, 1939 2,494,730 Thursby Ian. 17, 1950 FOREIGN PATENTS 537,251 Italy Dec. 19, 1955 

